Setup Reduction -- Creating More Production Time Dr. Richard A. Wysk [e-mail] http://www.engr.psu.edu/cim March 20, 2003

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Setup Reduction -- Creating More
Production TimeDr. Richard A.
Wyskrwysk_at_psu.eduhttp//www.engr.psu.edu/cimMa
rch 20, 2003
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Make it better!Make it faster!Make it cheaper!
Lets spend a few minutes and talk about how we
might make things better, faster and/or cheaper.
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HIGH
FLEXIBILITY
TRANSFER LINE
PRODUCTION CAPACITY
SPECIAL SYSTEM
FLEXIBLE MANUFACTURING SYSTEM
VOLUME
MANUFACTURING Cells
STD. AND GEN. MACHINERY
LOW
HIGH
VARIETY
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Readings

• Singo Shingeo, A Revolution in Manufacturing-The
  SMED-Single Minute Exchange of Dies-System,
  Productivity Press, 1981.
• Chapter 18 of Computer Aided Manufacturing, Wang,
  H.P., Chang, T.C. and Wysk, R. A., 3rd Edition
  (2004 expected) http//www.engr.psu.edu/cim/active
  /ie450ho1.pdf

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Objectives

• To be able to identify internal and external
  process elements
• To be able to apply methods improvements
  techniques to manufacturing
• To calculate/measure the various Production Time
  Elements
• To be able to apply the techniques of set-up
  reduction

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ExerciseReadiness Assessment Test A.K.A. RAT

• Complete the RAT for this module before you meet
  to discuss this for class.
• What set up reduction activities did you
  select as having value added to you for personal
  benefit?

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How long does it take to produce something?

• It is not unusual for the processing time to be a
  very small part of the time required to make a
  component.
• Order materials
• Accumulate parts
• Setup machine

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JIT -- Speed is everything!

• Some Just in time models
• Buying bread
• Buying milk
• Buying take-out

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Exercise

• What are the most important factors that
  contribute to the production time (average time
  required to produce a single unit/product)?

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In Industry

• Between .05 and 5 of the time Value is being
  added to a product

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What are the Value added activities at PSU Inc.?

• Receiving -gt
• Material handling -gt
• Machining -gt
• Assembling -gt
• Packaging

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Are we really adding value

• What percent of the time are the machines
  producing good product?
• What percent of the time are the moving and
  setting up?

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Producing a product

• Production time (per lot)
• setup time (per lot) manufacturing time (per
  lot)

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Producing a product

• Manufacturing time (per piece)
• material handling and locating time (per piece)
  manufacturing time (per piece)

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Product time (per piece)


Total production time S (set up time
load/unload time processing time
idle time tool change
time) initial set up time
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the time required for setup for an operation
(load fixture,
retrieve tooling , etc.)
L/UL
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Production time per piece

• The cost associated with new tooling is also a
  key consideration
• for the designer.
• For low and medium volume products, the cost
  associated with
• tooling and setup can dominate the total product
  cost.

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• The product cost can be expressed as
• Production cost per piece, Cp

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where
Cmo is the cost of machine and operator/hour Ct i
s the perishable tooling cost np/t is the number
of pieces that can be produced per
tool Csetup is the setup resource cost for the
part (fixture, jig, steady-rest,
etc) nbt is the total number of parts to be
produced
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Simple CNC Example

• New batch of parts arrives
• Change over tools for the batch
• Set offsets for new tools
• Load NC program
• Validate
• Run parts
• Load part onto machine
• Cycle start and wait
• Unload and visually inspect (adjust if necessary)

Setup time per lot
Material handling and loading time per piece
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Graphically it looks like
TOTAL TIME TO PRODUCE A LOT OF PRODUCT
SETTING UP THE MACHINE
RUNNING THE MACHINE AND OFF-LINE MEASUREMENT
This can be gt 30 of the TOTAL TIME TO
PRODUCE A LOT
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A look at SETUP
SETTING UP THE MACHINE
Setup consists of activities that must be
performed on the machine (these are called
Internal Elements), and elements that can be
performed off-line or while the machine is
producing a product (these are called External
Elements)
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Rapid Tool Change-over Setup consists of

• Internal Elements - Elements that must be
  performed on the machine itself
• External Elements - Elements that can be
  performed off-line

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A look at SETUP (contd)
SETTING UP THE MACHINE
Internal Elements
External Elements
These External Elements can be completed while
the machine is producing good product. For
instance, we can clean a die set after the
machine comes up. We can preassemble
components for a setup.
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A look at SETUP (contd)
SETTING UP THE MACHINE
Internal Elements
External Elements
RUNNING THE MACHINE
If the External Elements are performed while the
machine is producing good parts then we can
reduce the TOTAL PRODUCTION TIME by starting
production earlier.
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Premise for SMED
Idle time waiting for materials or other resources
Set up time where machine is down while
operators prepares for next activity
Processing time - adding value to raw materials
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Graphically it looks like
TOTAL TIME TO PRODUCE A LOT OF PRODUCT
SAVINGS
SETTING UP THE MACHINE
RUNNING THE MACHINE AND OFF-LINE MEASUREMENT
Production Time gained
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Premise for SMED
Methods improvements
Idle time waiting for materials or other resources
Set up time where machine is down while
operators prepares for next activity
Processing time - adding value to raw materials
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Exercise (5 minutes)

• As an individual, describe a process that you
  know well (from work, food preparation, office
  activities)
• Identify the internal and external elements for
  setup or work changeover.

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Methods Improvement

• Standard ways to improve setup efficiency
• Power tools
• Collets and quick-change fixtures
• 2nd set of fixtures and tools
• Setup layout
• Setup accumulation

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Examples of Improved Methods
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Make the tool part of the screw device -- you
dont need a tool, and this will save time in
disassembling and reassembling the tooling and
fixturing!
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Reduce the amount of turns required in order to
activate the screw.
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Reduce the amount of screw turns and eliminate
the tool!
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Areas with potential benefit

• Screws and screw fasteners
• Tedious manual activities
• Power tools can be appropriate
• Connectors
• Others????

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Currently changeover is done with these tools
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Currently changeover is done with these tools
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How about power tooling?
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How about cordless power tooling?
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Exercise

• As an individual, describe what methods,
  improvements, you could make to the setup/change
  over activity for the Case production system or
  some other system that you are familiar with?

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SMED is employee driven

• Train Area supervisors and operators
• Some implementation with outside consultant
• Most implementation within your company

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Questions?